Rotor Blade Foam Placement for Exothermic Curing
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Solution Overview
Problem
Conventional methods for producing rotor blades are costly due to the need for temperature-resistant foams, which are expensive and inefficiently used throughout the manufacturing process, especially during the exothermic curing reaction.
Innovation Solution
The method involves using a higher temperature-resistant foam in areas subjected to high curing temperatures and a lower temperature-resistant foam in areas with lower curing temperatures, optimizing foam placement based on temperature distribution during the resin impregnation and curing process, and selecting foams like PVC, SAN, or PU for high-temperature areas and polystyrene for low-temperature areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature-resistant foam is used throughout the entire rotor blade structure, then the foam can withstand the exothermic peak during curing, but the material cost increases significantly
Solution Approach 1:
The patent applies different foam materials with different temperature resistances to different regions of the rotor blade based on the local temperature distribution during curing. High-temperature-resistant foam is placed only in areas experiencing high exothermic peaks (multi-layer fabric regions), while lower-temperature-resistant foam is used in areas with lower temperature exposure (simple sandwich construction regions). This resolves the contradiction by providing sufficient temperature resistance only where needed, reducing overall material cost while maintaining reliability.
2Strength
If high-temperature-resistant foam is used in all areas, then structural integrity is maintained during curing, but production cost increases
Solution Approach 1:
The patent implements local quality by matching foam temperature resistance to the specific thermal conditions of each blade region. Multi-layer fabric areas generating high exothermic peaks receive high-temperature-resistant foam to maintain structural integrity, while simple sandwich construction areas with lower temperature exposure use cost-effective lower-temperature-resistant foam. This selective approach maintains overall structural integrity during curing while significantly reducing production costs.
3Ease of manufacture
If uniform foam material is used throughout the rotor blade, then manufacturing is simplified, but cost efficiency decreases due to over-specification in low-temperature areas
Solution Approach 1:
The patent applies local quality by differentiating foam material selection based on the structural composition and thermal behavior of different blade regions. The manufacturing process remains relatively simple by following the pre-determined temperature distribution map, but achieves cost efficiency by avoiding over-specification of high-temperature-resistant foam in low-temperature areas. This resolves the contradiction by optimizing material cost without significantly complicating the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material costs by using less expensive foams where lower temperatures prevail, maintaining structural integrity and mechanical properties, while ensuring the high-temperature-resistant foams withstand the exothermic peak without damage, thus producing a cost-effective rotor blade.
Implementation Method 1
a resin system is introduced into a dry, multi-layer fabric, which reacts exothermically within the semi-finished product and cures with the subsequent application of additional heat
Data Source
Figure 1
AI summary
The invention relates to a method for producing a rotor blade by arranging foam (23, 24) in a semi-finished product, introducing resin into the foam-containing semi-finished product, and curing the introduced resin while heat is dissipated and a curing temperature distribution is obtained, a first foam (23) being arranged in regions of the semi-finished product with a higher curing temperature, and a second foam (24) in regions with a lower curing temperature, and a foam with a higher temperature resistance than the second foam (24) being chosen as the first foam (23).